Balcrank JET POWER 1150-004 Instruction Manual

Thoroughly read and understand this manual before
installing, operating or servicing this equipment.
OPERATION, INSTALLATION,
MAINTENANCE AND REPAIR GUIDE
SERVICE BULLETIN SB1075
Revision B 3/10
JET POWER™PUMP
50:1 RATIO SERIES
High Pressure Grease
Models:
1150-004, Bare Pump, 25-35# Pail
1151-014, 25-35# Outt
1150-012, Bare Pump, 120# Drum
1151-013, 120# Outt
1151-015, 120# Outt
1151-016, 120# Outt
1150-013, Bare Pump, 400# Drum
1151-017, 400# Outt
®

2
!
!
General Safety
Because this pump can be
incorporated into a pressurized
systems, the following safety
precautions should be observed.
Check equipment regularly and repair or
replace worn and damaged parts.
Never alter or modify any parts of this
pump, doing so may cause damage to pump
and/or personal injury.
Under no circumstances should the
dispensing valve be aimed at any person at
any time. Personal injury may result.
Release pressures built up in the system
before any service or repair is begun. See the
pressure relief procedure below.
Do not operate this pump above 150 PSI
(10.3 BAR) air inlet pressure or 200 cycles per
minute.
Always read and follow the uid
manufacturer’s recommendations regarding
the use of protective eyewear, clothing and
respirators.
IMPORTANT
!
Pressure Relief Procedure:
Follow this procedure whenever you shut
off the pump, when checking or servicing any
part of the system and when installing, cleaning
or changing any part of the system.
1) Disconnect the air to the pump.
2) Point dispensing valve away from
yourself and others.
3) Open dispensing valve until
pressure is relieved.
WARNING
!
WARNING
!
THIS PUMP CONTAINS
ALUMINUM AND ZINC
PARTS. DO NOT use 1-1-1
Trichloroethane, methylene chloride or
other halogenated hydrocarbon solvents
or fluids containing such solvents in this
pump. Use of these solvents/fluids may
result in a violent chemical reaction, causing
serious bodily injury, property damage
or death. All fluids used in this pump
must be chemically compatible with the
wetted parts materials shown on page two
(2) of this manual. Consult your chemical
supplier to ensure compatibility.
WARNING
!
WARNING: The Jet Power™50:1
grease pump develops up to 7500 psi (517 Bar)
maximum working pressure at 150 psi (10.3 Bar)
maximum inlet air pressure and stall conditions.
Be sure that any components or accessories used in
the system are rated to withstand this pressure. To
determine uid output pressure at stall conditions,
multiply the ratio of the pump by the air pressure
being used.
EXAMPLE: 50:1 Pump Ratio x 100 psi air
pressure = 5000 psi uid pressure at stall.
WARNING
!
DANGER: Not for use with
fluids that have a flash point
below 100°F (38°C). Examples:
gasoline, alcohol. Sparking could
result in an explosion which could result in
death.
In the presence of explosive
vapors, take action to prevent
static sparking. Failure to
ground the pump, piping, valves, containers, or
other miscellaneous equipment can result in re or
explosion. A green grounding lug is provided on the
pump.
WARNING
!
WARNING
!
Use 3241-002 Pump Over-Run
control valve on pump air inlet for remotely
operated pumps. Failure to use this valve can
cause pump to cycle quickly when barrel is
empty of grease. THIS WILL DAMAGE THE
PUMP and may void factory warranty.
Thoroughly read and understand this manual before
installing, operating or servicing the described prod-
ucts.

3
PRODUCT DESCRIPTION
The Jet Power™Pump is a Balcrank®time tested, reliable pump with a 50:1 ratio and a large
diameter air piston rated for 150 psi continuous duty. The Jet Power™Pump is suitable for grease
distribution to multiple dispensing points or for dispensing distances up to 300 feet.
The Jet Power™Pump air motor features precision cast aluminum allot parts, it has a simple
durable construction with all internal parts lubricated ad the factory with a life tested synthetic
grease (Balcrank Part # 826733). This grease coats all internal parts and repels air line moisture
to inhibit corrosion.
The Jet Power™pumping assembly features steel pump rods, tubes, and high quality grease seals
and packings and a shovel type primer piston all incorporated in a precision built assembly.
TECHNICAL DATA
Pressure Ratio................................................................................................................................50:1
Air Motor Bore ..................................................................................... 3.38” (effective diameter 2.62”)
Stroke ........................................................................................................................................... 2.12”
Operating Air Pressure Range....................................................................40-150 PSI (2.7-10.3 BAR)
Air Consumption (@100 psi) ...................................................................................................50 CFM1
Air Inlet Port Size............................................................................................................................ 1/4”
Material Outlet Port......................................................................................................................... 1/4”
Wetted Parts..................................................................................... Steel, Buna-N, Brass, Ultrathane
1. Air consumption varies with pump speed.
DELIVERY PER MINUTE, LBS
LUBRICANT @750F @400F
Lightbodygrease ................................3.0..............2.5
Viscousgrease ..................................2.5..............1.8
Fibrous grease...................................1.5..............1.2

4
INSTALLATION
Remove pump from carton and attach to cover,
bung tting or other mounting.
Blow out any foreign material from the air supply
line before connecting to pump. An air line lter/
regulator is recommended for all applications;
wet and dirty air will shorten the life of the pump.
For severe duty applications, an air line lubricator
is recommended for better performance and
longer pump life. Use 10 to 20 weight lubricant
and set for 1 drop every 2 minutes of use.
Be sure air supply is off before connecting to
pump. Gradually open air regulator valve until
pump begins to cycle. The pump should prime
within 1 to 3 minutes. Pump a small amount of
uid at low air pressure to remove trapped air
and foreign materials from lines. Discard this
waste material.
Consult with local and state authorities to
determine proper disposal of waste material.
After the pump system is fully primed, open air
supply valve until desired ow and/or pressure
is obtained. Always use the lowest pressure
needed to obtain the desired results. This
reduces pump wear.
TROUBLESHOOTING
Read all instructions carefully before servicing.
If pump does not operate properly, check the
following points carefully (before making any
adjustments or repairs) to determine which part
of the installation is at fault.
I. (a) Is pump getting an adequate supply of air?
Connect air gauge to coupler. Pumps should
develop grease pressure approximately 50
times the air pressure used. Most practical
grease pressure is developed by 150 pounds
of air pressure.
(b) Check air coupler to pump to make sure
it is connected securely.
II. Check grease drum to make sure pump tube
is submerged in lubricant. Change drum
if necessary.
III. Check grease line for leaks in hose, swivels,
connectors, control handle, and pipe line.
Pump will operate continuously to replace
leaking grease.
After preceding points have been checked,,
proceed as follows with the case or cases which
appear to meet your situation.
CASE 1: Pump not operating at all (air valve
(38) not tripping over) or air blowing constantly
from air valve.
A. Toggle of air valve assembly may be rubbing
against tripper rod (6) and the friction is
preventing it from tripping. In some cases,
it may only be rubbing a little and when the
pump is running free, the toggle is moving
fast enough to overcome friction, but when
the pump builds up pressure and slows down,
the toggle will stick. Remove air valve by
unscrewing two cover screws (19) and six
clamp screws (17). Carfully pry the toggle
away from the pump body with screwdriver.
B. The six screws (17) holding the air valve
assembly to the casting may be loose;
tighten them securely. In most cases, the air
valve assembly will operate if these screws
are loose, but it will be sluggish and air will
probably leak. The same thing will happen if
gasket (14) between the air valve assembly
and the pump casting is damaged or worn.
C. If air valve assembly (15) still will not
operate, it will be necessary to replace it.
Replacement is very simple and the cost is
reasonable. Parts for the air valve are not
sold individually.
CASE 2: Hose pulsating with absence of grease
under pressure. This is an indication that the
primer valve (43) or ball (34) are not seating
properly. Also Check ball outlet assembly at
point of hose attachment as ball (47) may not
be seating properly.
A. To clean ball seat and piston adapter,
proceed as follows: Unscrew screen (4430-
001) at lower end of tube with pipe wrench, if
applicable, grasping same at extreme lower
end. Loosen primer cylinder (44) with pipe
wrench but do not remove. Line up slots
in primer cylinder with small hole (3/16”)

5
in primer rod (38). Insert 5/32” steel rod or
punch through slot of primer cylinder and hole
in primer rod.
B. Unscrew nut (40) and pull off primer piston
(39). Remove steel rod or punch and unscrew
primer cylinder (44) previously loosened.
Unscrew high pressure cylinder (42) and slide
off rod. Primer valve is inside this cylinder.
Push out with small rod or screwdriver.
Inspect for dirt, clean thoroughly.
C. Unscrew primer rod (38). Pull off brass
bushing (37) and u-cup seal (36) in order.
Inspect packings for wear, replace if
necessary. Unscrew piston adapter (35)
and tap out spring (33) and ball (34). Clean
ball and piston adapter thoroughly. Reseat
ball, using soft metal rod and tapping lightly
with small hammer. Reinstall the spring (33)
ensuring that the tapered end is towards the
ball (34)
To clean outlet ball check, unscrew outlet
retainer (45) and remove ball stop (46) and
ball (47). Clean ball and seat thoroughly and
reseat as described above.
Reassemble and pump is ready for use, no
priming necessary.
CASE 3: Air escaping around air piston guide
(2). This is an indication that the two o-rings (5)
or the o-ring (8) are damaged or worn.
A. Remove the four screws (1) which attach the
air piston guide (2) to the air cylinder body
(13) and lift off air piston guide. Unscrew two
bolts (3) which secure tripper rod arm (6)
to the air piston (9). Lift off tripper rod arm
and replace bolts (3). Using a screw driver
or metal rod across air piston and between
heads of bolts, unscrew air piston (9) from
pump rod (31). Pull air piston and retainer
ring (7) from air cylinder body (13). Slide
retainer ring (7) off air piston and inspect
upper and lower o-rings (5) and o-ring (8) for
wear. Replace if necessary.
Reassemble and pump is ready for use.
CASE 4: Grease escaping through air valve
and port in base of pump or air blowing through
port in base of pump into grease drum. This is
an indication that the packings in the lower air
cylinder body are damaged or worn.
A. Remove primer tube, rod, etc. as outlined
in CASE 2.
B. Unscrew packing nut (49), Unscrew pump
rod and pull from air cylinder body. The pump
tube adapter (30), hydraulic u-packing (29),
rubber backup washer (28), plastic packing
washer (27), packing spacer (26), spring (25),
wiper casing (24), wiper (23) Stop (22), o-ring
(21) and gasket (20) should pull out with rod.
If not, pull out by using a wire with a small
hook on it.
C. Inspect for wear and replace damaged or
worn parts. Reassemble and pump is ready
for use.
NOTE: Outlet body (48) screws into pump
tube adapter (30) and must be replaced prior
to tightening packing nut (49) and pump tube
as outlet must be lined up with opening in air
cylinder body.
If you cannot distinguish your difculty or if after
trying the remedial procedure without material
success, call your nearest Balcrank Authorized
Service Center.
Revision Log:
New Release - 8/06
Rev. A - Added note to item 33 on page 7
Rev. B - Corrected item numbers for Cases 1-4 on
pages 4 & 5

6
PARTS LIST
ITEM PART # DESCRIPTION QTY 816348
1 823867 Screw, PHP, 10-24 X 7/8 4
2 830006 Cap 1
3 807532 Screw, SHC, 1/4-28 x 5/8 2
4 806512 Tripper Rod Arm 1
5 806906 O-Ring, Buna N, -337 3 2
6 807388 Tripper Rod 1
7 807390 Retainer Ring 1
8 814075 O-Ring, Buna N, -153 1 1
9 807387 Air Piston 1
10 807465 Square Nut 1
11 807448 Clamp Nut 1
12 806015 Pipe Plug 1
13 807537 Air Cylinder Body 1
14 821957 Gasket 1
15 810071 Air Valve Assembly 1
16 806265 Lock Washer 6
17 806132 Screw, SHC, 8-32 x 3/8 6
18 823185 Valve Cover 1
19 823867 Screw, PHP, 10-24 x 7/8 2
20 807482 Gasket 1 1
21 806895 O-Ring, Buna N, -112 1 1
22 807488 Packing Stop 1
23 806812 Wiper 1 1
24 807517 Wiper Casing 1
25 807515 Packing Spring 1
26 807490 Packing Spacer 1
27 808488 Teon Packing Washer 1 1
28 808444 Rubber Back-up Washer 1 1
29 826782 Packing 1 1
30 807394 Pump Tube Adapter 1
31 808327 Upper Rod 1
32 812208 Rod (1150-004) 1
808329 Rod (1150-012) 1
808332 Rod (1150-013) 1
33 807454 Valve Spring 1 1
34 806289 Ball, 7/32 1 1
35 828469 Piston Adapter 1 1
36 829154 U-Cup 1 1
37 828528 Brass Bushing 1 1
38 807408 Primer Rod 1
39 807410 Primer Piston 1
40 806467 Hex Nut 1
41 812209 Upper Tube (1150-004) 1
831894 Upper Tube (1150-012) 1
831893 Upper Tube (1150-013) 1
42 831897 High Pressure Cylinder 1
43 807406 Primer Valve 1
44 832100 Primer Cylinder 1
45* 827698 Retainer, Outlet 1
46* 807162 Ball Stop 1
47* 807549 Ball, 11/32 1
48* 807545 Outlet 1
49 807483 Packing Nut 1
*Contained in 809696 assembly

7
EXPLODED VIEW
1
2
3
4
56
7
8
5
9
5
10
11 12
13
14 15
16 17 18
19
20
21
22
23
24 25
26
27 28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
ACCESSORIES
4440-006
4440-010
4440-011
4430-001
Deep chamfer up
Cup-up
3241-002
NOTE: Spring is
directional; tapered end
towards ball.

Balcrank®Corporation
Weaverville, NC 28787
800-747-5300
800-763-0840 Fax
www.balcrank.com
SERVICE BULLETIN SB 1075
Rev. B 3/10
832156
For Warranty Information Visit:
www.balcrank.com